Volkswagen

Removing engine cover 2.0T FSI - VW GTI GLI JETTA AUDI A3 - 2006 VW Jetta GLI 2.0T FSI

Removing MKV engine cover 2.0T FSI

I had a little issue today that I had to troubleshoot, so I took some pics. I think there's some general directions, but here's details with pics:

1. Unclip the two metal clips.
2. Unclip the MAF sensor and pull out of the way.
3. Undo the air intake or undo the clip right behind the box area.
X. Pull. Cuss. Repeat. After a few attempts, pull harder and wiggle cover out.

2.0T FSI Engine Cover

These are the mount points (4 of them) on the engine. If there are any rubber pieces on the posts, pull them off and put them in the cover before re-assy.

Posted in Submitted by deviantspeed on Fri, 2006-11-17 19:09.
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Fog Lights - 2006 VW Jetta GLI 2.0T FSI

Fog Lights - 2006 VW Jetta GLI 2.0T FSI

How to change your fog light bulbs on your 2006 VW GLI or GTI. First of all, we need to address the replacement light bulbs. On the USA market GLI/GTI's we are seeing 9006 Bulbs. There are aftermarket jetta kits that have hit the market, and they are coming with H11 bulbs. There have been factory MKV's that have come with H11 or 9006 bulbs. The only way to be 100% sure is to open yours up first. It should take no more than 15 minutes to check them.

Let's start by removing the set screw on the lower panel.

Posted in | Submitted by deviantspeed on Fri, 2006-11-17 19:06.
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GIAC Chip and Dyno - 2006 VW Jetta GLI 2.0T FSI

GIAC Chip and Dyno - 2006 VW Jetta GLI 2.0T FSI

We equipped our Jetta GLI with a GIAC chip.
A vag-com block 120 "dyno" was done after the installation. Usually the vag-com dyno is spot on with matching wheel output. As you can see here, the engine generates a lot of torque:

GIAC FSI 2.0T Chip Results

GIAC Dyno, Jetta GLI

As you can see, the results are rather impressive for 4 door vw!

Here's some more data:


Another 3rd gear dyno:
Giac dyno vw

Requested boost vs. Actual - boost does die down on small factory turbos fast!

boost graph

Air/fuel ratios - rather lean for just a chip. Word has it that GIAC is working on and testing leaner files in the real world right now. There is still much to learn about the 2.0T FSI engine, so I'm glad they are doing a lot more testing before upping the parameters.

Posted in | Submitted by deviantspeed on Fri, 2006-11-17 18:59.
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Suspension - H&R Cup Kit - VW GTI 1.8T

Suspension - H&R Cup Kit - VW GTI 1.8T

The H&R Cup Kit is a set of lowering springs that are between sport and race settings, and a set of struts/shocks matched to the springs. Due to demand and effectiveness of the kit, the cost is actually not that bad! You can find the kit at most retailers for about $575.


Aggressive looks even on the stock rims and tires!


A cup strut ready to go in. Here, the upper rubber was replaced with the VW Motorsport supports (manufactured by Bilstein, in the red box)

Posted in | Submitted by deviantspeed on Fri, 2006-11-17 17:42.
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Turbo Information for the VW GTI 1.8T Turbo Engine

The turbocharger used on the 1.8T VW's is the Borg-Warner KKK03. The K03 turbo is a smaller turbo, capable of spooling up much quicker than other traditional turbos. Stock, the engine/turbo combination produces 150hp, with 150ft/lbs of torque that kick in at about 1750 rpms; all at a safe 7psi. The beauty of the engine is that torque stays on all the way through the rpm range, so full torque is available through almost all of the rpm range. This makes the car a joy to drive, with smooth consistent power always available.

Now add chip tuning to the equation. For about 500 dollars, chip tuners modify your ecu to perform at different levels. In the past, this meant a few percent gain in hp. Boost management is handled by the ECU, so chip tuners are able to generate massive amounts of power by modifying the stock programming. On the stock program, the turbo generates about 5-7 psi. For example, with the GIAC 1.1 bar chip, your car will now make about 15-16 psi of boost pressure. Under loaded conditions, the GIAC can spike at up to 20 psi. What does this all mean? Increasing your power by about 33% with just the chip makes large amounts of HP and torque available immediately. HP is up by about 47 over stock, and torque is increased by up to an amazing 90 ft/lbs!!!! For most drivers is simply the easiest, most effective power upgrade available.

Posted in Submitted by deviantspeed on Fri, 2006-11-17 17:38.
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ATP 3" Downpipe - VW GTI 1.8T

ATP 3" Downpipe - VW GTI 1.8T

Shown here is the 3" downpipe with the Race Section that replaces the cat. **for off-road use only**

Posted in Submitted by deviantspeed on Fri, 2006-11-17 15:51.
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Intercooler Mister - VW 2000 GTI 1.8T

Intercooler Mister - VW 2000 GTI 1.8T

Living in Las Vegas means one thing when the sun is out... hot 100°+ days. Cars struggle in this heat, many burst radiator lines, and others just lose power with the increase in heat. I was desperately looking for a helping hand with my 1.8T engine this summer, and I stumbled upon the Autospeed Intelligent Intercooloer Water Spray Controller Module. After some research I came up with all the necessary items to put this electronic marvel together and make it work.

The Autospeed Intelligent Intercooler Water Spray Control Module works off a combination of events that trigger power to a separate water pump. The first of these inputs are two temperature sending units that monitor ambient and intercooler temperature. There are adjustments to fine tune an event based on temperature differences between these two sensors. The second input is a reading off of a fuel injector. The unit is also adjustable, but will only trigger an event when a certain amount of fuel is being dumped into the engine. When both of these inputs are triggered, the pump goes of for a time period based on input from the sensors. Usually this means that during the time you are at WOT, the pump will spray water onto the intercooler. When you shift and get on the throttle again, the unit is intelligent enough to keep the spray going. So when you WOT in the next gear, your intake temps are MUCH cooler than what they would be without a mister!

The plumbing took some trial and error to get perfect. I'll start with the basics:

  • Washer pump, universal
  • Several feet of 1/4" tubing
  • Spray nozzle with a "crack valve"

Unfortunately, it took me a while to get to the final product. I started with some Arizona Mister sprinkler heads, that tapped into the 1/4 hosing very easily. A few 1/4" connectors, zip ties, and an aquarium check valve got me into business. I also mounted the ambient temp sensor in the grill piece, hence the wires in the picture below:

intercooler misting system

During my first heavy trial run, I broke the aquarium check valve, so water was leaking when I parked the car. Fortunately I had a spare, but inevitable doom would have a short life for the second valve.

Labtronics Intelligent Intercooler Misting System

With a minor leak I decided to contact a real valve supply place for a better solution than the sprinkler ends. I came across a company (who wants to remain anonymous until they get a kit together) that was extremely knowledgeable, and knew exactly what I was doing. They came up with a completed unit. This unit had a fitting, the crack valve, and the nozzle all in one, and had a very large 3/8" hose inlet. Here it is side by side with the original spray head:

So after putting this in place, it does not leak, and sprays just as fine a mist as the other one, but flows more volume in a better pattern.

Posted in Submitted by deviantspeed on Fri, 2006-11-17 15:45.
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Euro split side mirror - VW 2000 GTI 1.8T

Euro split side mirror - VW 2000 GTI 1.8T

The Euro Split Side Mirror allows one to see into their blind spot much easier than with the stock glass. The mirror also has the connectors for the heated glass. Part is 1J1 857 521 C (off the box, and has the audi and vw logo on the box)

You can get them from "Potterman" at Parts4VWS.com

euro split mirror 1J1 857 521 C

Posted in Submitted by deviantspeed on Fri, 2006-11-17 15:39.
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Mintex brake pad install - VW GTI 1.8T

Mintex brake pad install - VW GTI 1.8T

Directions for installing the Mintex brake pads. These pads seem to grip a little better than stock, and most importantly, they don't shed brake dust all over the wheels!! Use this faq at your own risk. No guarantees are given or implied, all standard disclaimers.... If you don't know what you are doing, take this to a professional!


Supplies

  • (1) Set of Mintex brake pads, available in a few flavors
  • (1) Brake backing material (blue can spray type works great)
  • (1) crimp connector
  • (1) electrical tape and shrink tubing
  • (1) 7mm Hex key (preferred on the socket variety

Steps

Posted in Submitted by deviantspeed on Fri, 2006-11-17 15:36.
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Motion Sensor Install - VW GTI 1.8T

Motion Sensor Install - VW GTI 1.8T

This faq will document how to install a "radar" type motion sensor to the factory alarm on the MKIV VW's, this should cover GTI/golf/jetta/new beetle. The sensor uses radar to detect movement within the vehicle. A standard shock sensor can be added to the trigger too.


Tools:

Torx T-20 screwdriver

A few wire jumper connectors to tap into the wires.

DEI dual stage radar sensor (since DEI makes about 90%+ of alarm equipment, any store should carry this.

Remove the lower factory plastic pieces under the steering wheel. There are two parts on the lower part of the dash that are held in with the Torx screws. Remove all the screws and if you pry gently, you will see how they are removed. You will see a steel plate that can be removed after this. Once this is removed, you have access to the entire lower area.

Posted in | Submitted by deviantspeed on Fri, 2006-11-17 15:32.
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